Overmolding Services

Q: 1. What’s the process for injection mold making?

Our mold-making process includes 6 steps: Step 1: Production arrangement: Determine all of the requirements and arrange the production. Step 2: DFM report analysis: Provide free but detailed production DFM report for further feasibility analysis. Step 3: Production the mold: Put the mold into production and provide the Tooling Schedule form for the whole cycle for clients to check the process at any time. Step 4: Free sample to test: Put the mold into production and provide the Tooling Schedule form for the whole cycle for clients to check the process at any time. Step 5: Mass production:Client confirms the samples are qualified, then officially proceed with the subsequent production. Step 6: Mold saving: Production is completed and delivered after quality inspection. Mold will be cleaned and properly stored for the next round of parts production.

High-quality custom overmolding services for prototypes and on-demand production parts. Get online quotes, short cycle time and competitive pricing.

30t-1800t

Molding Machine

12

Surface Finishes

0pc

MOQ

0.025mm

Tolerances

Custom Overmolding Services

The overmolding process involves molding one plastic material over another. This ensures a seamless combination of multiple plastic parts to give a uniform and durable product. Insert molding and multi-shot molding processes help combine materials for functional and aesthetic purposes. RapidDirect’s plastic injection overmolding uses these processes to ensure every component meets industrial standards.

Improved Design and Creation of Custom Plastic Parts: Overmolding capabilities ensure the creation of custom plastic-plastic or metal-plastic product combinations with a high dimensional quality.
Better Product Performance: Overmolded parts are of excellent quality because of their two-material advantage for various applications.
Increased Shelf and Aesthetic Appeal: The overmolding process can be optimized with many materials and surface treatment processes to improve the aesthetic quality of the product.
Better Shock Absorption and Overall Durability: Overmolding also offers improved shock absorption due to the plastic resin addition, ensuring longer shelf life and excellent resistance against impacts.
Lower Production Costs: Since overmolding eliminates post-assembly phase of production, it speeds up the production process and reduces overall manufacturing cost.

Quote Within One Day, Operate at Your Fingertips

RapidDirect provides a AI-powered, hassle-free online quotation platform that can help simplify your ordering and manufacturing process. Stop wasting time in emails, get interactive quotes with DFM analysis within seconds, optimize your orders immediately, compare your multiple quotes side by side, manage your orders in one place.

Bulk Pricing

Get in-bulk quotes, allowing you to make a pricing comparison between different specs, quantities, raw materials, and surface finishes, and helping you choose the solution that best suits your needs and budget.

Real-time Order Tracking

Our online platform enables real-time visibility of the production flow that fosters more efficient operation monitoring and quicker response to negative changes.

All-in-one Order Management

Quickly check, search, and manage all your orders in one place. What's even better is that you get visibility into all stages of the production process and every aspect of the manufacturing operation.

Overmolding from Prototyping to Production

Rapid Tooling

Get easy design feedback and validation through superior quality prototype tooling. Create small batches of plastic molded parts with excellent injection molding prototypes. We excel at manufacturing prototype molds within days to ensure you perform functional tests and validate market interest.

Production Tooling

We create high-quality production molds for high-volume plastic parts production. With high-strength, durable tool steel material, our production tooling is suitable for producing hundreds of thousands of parts. We can vary materials and construction methods according to your unique requirements.

RapidDirect Overmolding Capabilities

RapidDirect’s custom overmolding services ensure the creation of plastic parts that look and perform better. Our production line consists of an overmolding injection molding process that allows us to combine several different materials into one, ensuring you get superior-quality products.

Standards	Metric Units	Imperial Units
Maximum Part Size	200×400×100mm	7.87×15.75×3.94in.
Minimum Part Size	2×2×2mm	0.08×0.08×0.08in.
Substrate Wall Thickness	From 0.5 to 3mm	From 0.20 to 0.12 in.
Tolerance	+/- 0.025 mm	+/- 0.00098 in.
Radii	0.1mm	0.0039in.
Depth	100mm from the parting line	3.94in. from the parting line
Mold Validation	Provide T0, T1, T2 samples before mass production
Inspection and Certification Options	First Article Inspection, ISO 9001, ISO 13485
Lead Time	From mold making to sample delivery: 15-45 business days

Materials for Overmolding

RapidDirect’s overmolding service incorporates choosing the right materials, ranging from thermoplastics to exotic resins. There are multiple possible combinations of overmolding materials and substrates. Here are some of the most common materials we use for the plastic overmolding process.

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Tooling Materials
Plastic Materials
Additives & fibers

Tooling Materials

Before the overmolding process starts low or high-volume production, a high-tolerance CNC machined tooling is needed. Most commonly used materials include:

Tool Steel: P20, H13, S7, NAK80, S136, S136H, 718, 718H, 738

Stainless Steel:

420, NAK80, S136, 316L, 316, 301, 303, 304

Aluminum: 6061, 5052, 7075

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Plastic Materials

Plastic injection molding service comes with a wide range of materials with different properties, including impact strength, rigidity, thermal resistance, chemical resistance, etc.

ABS	Nylon (PA)	PC	PVC
PU	PMMA	PP	PEEK
PE	HDPE	PS	POM

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Additives and Fibers

Standard plastic materials may not meet custom injection molding parts requirement. In this case, additives and fibers can be added to improve aesthetic and functional properties, providing additional features for your injection molded parts.

UV absorbers	Colorants
Flame retardants	Glass fibers
Plasticizers

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Note: You can learn more from our eBook on plastic materials.

Surface Finishes of Overmolding

Improve the quality of your overmolded parts with excellent surface finishes. RapidDirect offers a long list of surface finishing options to improve the cosmetic quality of your products. We provide exceptional secondary operations to improve the overall quality of products.

Name

Description

Link

Glossy	A grade finishes are made using a diamond buffing process and yield shiny and glossy surfaces on injection molded parts.	Learn More>>
Semi-glossy	B grade finishes use grit sandpaper to produce parts with a slightly rougher finish than grade A parts. Custom molded plastic parts that undergo B grade finishing have a matte surface texture.	Learn More>>
Matte	C grade finishes use grit sanding stones to produce a rough, uneven surface. Injection plastic parts that undergo C grade finishing have a matte surface texture.	Learn More>>
Textured	D grade finishes use grit and dry glass beads or oxide to produce a very rough textured finish. Depending on the type of material used, products can have a satin or dull finish.	Learn More>>

Injection Molding Whitepaper

Understanding the injection molding process can help designers and engineers create parts that are optimized for manufacturing, which can reduce costs and improve quality. Our ebook offers practical guides and tips that will help you achieve outstanding and durable injection molded parts.

Download it Now

Applications of Overmolding

The injection overmolding process is compatible with a wide variety of materials, ranging from plastics to metals. This process helps produce custom prototypes and production parts for various applications depending on your requirements. Several industries find valuable uses for overmolding services.

Surgical Instruments

Overmolding meets the precision and safety requirements of the medical industry. The ability to combine plastics and metal materials ensures the efficient creation of surgical devices, equipment housing, catheters, syringes, and more.

Electrical Applications

Using thermoplastic elastomer as an overmold material makes the process useful for electrical components. Custom-made overmolded parts, like electrical outlet covers, gaskets, etc., are made to withstand harsh conditions, making them last longer.

Hareware Tools

The functional advantages of overmolding make it an outstanding process for making pliers, screwdrivers, hammers, wrenches, pocket knives, and more. The process improves the grip of these tools, making their application more efficient.

Household Items

The overmolding technique generally improves functional performance like grip, cleanliness, and ease of use. It also enhances vibration dampening, chemical resistance, and more. This makes them useful for household items like kitchen utensils, toothbrushes, pens, shampoo bottles, etc.

Gallery of Overmolded Parts

Why Choose RapidDirect

We take an approach that aims to meet your customized needs. We aim to provide long-term prototype overmolding solutions to engineering experts and project managers from design to production. RapidDirect combines cost-effective mold tooling with tech-driven overmolding services that help to make high-quality parts.

See What Our Customers Say About Us

A customer’s words have a more substantial impact than a company’s claims – and see what our satisfied customers have said regarding how we fulfilled their requirements.

We have been working with RapidDirect for years. They have helped us overcome many mold design issues and have enabled us to meet our quality goals. Their quality systems are really up to par and the production parts have exceeded our expectations.

Keith Laurie

-Tooling Design Engineer

RapidDirect has been our molding partner for over 2 years. Since then, RapidDirect has regularly provided us with top-notch molded parts. In addition, RapidDirect has offered assembly services for various models of our multi-bit screwdrivers up until the final finished product. I am pleased to recommend RapidDirect to anyone looking for top-notch molded products.

Harri Rossi

– Engineer

The staff at RapidDirect has assisted us in turning our ideas into finished parts for several years now. The process from conception to manufacturing has been smooth, thanks to their knowledge, skills, and “can-do” attitude. This is one of our most fruitful business partnerships because of RapidDirect’s emphasis on customer satisfaction.

Jimmy Kowalski

– Lead Mechanical Engineer

RapidDirect has consistently proved to be a top supplier of injection molded parts for our company. They have constantly impressed us with their professionalism, fairness, and reasonable prices. We’ve hired RapidDirect to create molds for us, fix and adapt existing molds to suit our demands, and deliver items that consistently meet or surpass our strict specifications.

Marcel Ransom

– Designer

RapidDirect has been a wonderful and strategic partner for us right from the beginning. They listen to customers and respond with a high level of technical expertise in materials, part design, and process options. This has been and will continue to be a crucial component of our success.

Danny Smajic

– Director of Product Development

Play Video about insert molding vs overmolding

Overmolding vs Insert Molding

While there are various similarities between overmolding and insert molding, there are also certain differences you must note. Here’s a video to explain the vital differences between these valuable processes.

Our Overmolding Service for Various Industries

RapidDirect works with leading manufacturers from different industries to support growing demands and streamline their supply chain. The digitalization of our custom injection molding services helps more and more manufacturers bring their idea to products.

Automotive

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Aerospace

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Consumer Goods

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Medical Devices

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Robotics

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Let's Start A New Project Today

Frequently Asked Questions

1. What’s the process for injection mold making?

Our mold-making process includes 6 steps:

Step 1: Production arrangement: Determine all of the requirements and arrange the production.

Step 2: DFM report analysis: Provide free but detailed production DFM report for further feasibility analysis.

Step 3: Production the mold: Put the mold into production and provide the Tooling Schedule form for the whole cycle for clients to check the process at any time.

Step 4: Free sample to test: Put the mold into production and provide the Tooling Schedule form for the whole cycle for clients to check the process at any time.

Step 5: Mass production:Client confirms the samples are qualified, then officially proceed with the subsequent production.

Step 6: Mold saving: Production is completed and delivered after quality inspection. Mold will be cleaned and properly stored for the next round of parts production.

2. What are the typical tolerances for injection molded parts?

Tolerance is very important, and if not correctly specified and controlled, assembling will fail. RapidDirect uses ISO 2068-c standard for injection molding tolerances unless tighter tolerance required.

3. What is the minimum order qty?

No minimum order quantity, but the oder pricing will be more competitive if qty is higher.

4. How long does it take to make molded parts?

After you place order, it takes about 35 days for mold designing and making, and more 3-5 days for molded parts production.

5. How much does your injection molding service cost?

Generally, we generate the quote after our platform must have considered several factors, including the size of the component, mold complexity, number of injection cavities, materials, post-processing needs, etc.

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Overmolding from Prototyping to Production

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Materials for Overmolding

Tooling Materials

Plastic Materials

Additives and Fibers

Surface Finishes of Overmolding

Applications of Overmolding

Surgical Instruments

Electrical Applications

Hareware Tools

Household Items

Gallery of Overmolded Parts

Why Choose RapidDirect

No MOQ

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Consistency and High Quality

Overmolding Specialists

See What Our Customers Say About Us

Overmolding vs Insert Molding

Our Overmolding Service for Various Industries

Automotive

Aerospace

Consumer Goods

Medical Devices

Robotics

Let's Start A New Project Today

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